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Tips for Grading a Culvert through Motor Graders

A culvert is constructed either for cross-ditch relief or to allow the road to cross a natural stream or drainage area.

Generally, culverts are built at the time of the new road construction and take the form of one or more pipes or other conduits. They are fully embedded in the soil below the road bed. With the right attachments, motor graders can play a very important role in constructing, repairing and unblocking culverts.

The importance of culverts in road maintenance

In order to keep the road safe and in usable condition for a longer period of time, both culverts and ditches play an important role. In fact, without them, the road surface may be damaged due to even fairly small or seasonal flows of water. Further, it is seen that the water which is gathered on the road as a pool can hamper the vehicular traffic and lead to vehicle tires losing their grip on the road surface. This can result in major accidents as the potentially dangerous potholes or obstructions may be hidden due to the pooled water on road. Culverts help in avoiding such a situation.

If the culverts are placed strategically along with the road ditch turn-outs, then they can help in maintaining a stable velocity and the proper flow capacity for the road ditches by timely outleting water from them. This can greatly reduce the need for road maintenance by not allowing roadway flooding and reducing erosion. What more? By letting the water drain from the ditches along the road and keeping the sub-base dry, culverts preserve the road base to a very large extent.

As per the experts, in order to ease the water problem on roads and be effective, appropriate sized culverts should be built. This generally depends on the quantity of water that the culvert may have to drain. In addition, it is to be noted that the culvert should be laid in a correct position and the surrounding slopes and drainage area should be graded and reinforced.

Culvert grading tips

Grading a right culvert through a motor grader is not an easy task and it requires good amount of pre-planning. In fact, for building a large culvert or a culvert for a major road, it is necessary to do proper site analysis and engineering. While grading a culvert is a complex process, here are some general tips for smaller culverts (generally required on forest and other dirt roads) construction and grading…

1. Typically, bed of gravel or soil should be laid such that it is at least one-quarter the diameter of the culvert pipe. It should be seen that the bed and fill material should be free of large rocks.

2. It should be taken care of that the bed should not be below the water runoff channel. In fact, if the culvert is positioned too low, then it is more likely to accumulate soil and get blocked.

3. Corrugated metal pipe should not be laid directly onto the rock as it does not have the required flexibility and can often damage the centre of the pipe which generally takes the maximum load. Concrete pipe should be used when there is no other option.

4. In the centre of the pipe, a camber should be incorporated to protect it from the pressure exerted by a fill or embankment.

5. In order to prevent soil and other debris from getting accumulated, the culvert should be sloped using about 3 per cent grade. Here, it should be kept in mind that such a grade should be used that does not change the speed of the water’s natural flow significantly.

6. The culvert should be positioned at the same grade as the ditch to be drained if the culvert would be used for drain relief purposes.

7. The culverts used for ditch relief should not be skewed more than 45 degrees to the centre line of the road. This is to ensure that the water is not forced too far off its natural course.

8. For corrugated metal pipe, the culvert should be covered with soil to a depth of at least 30 centimetres and minimum 60 centimetres for concrete pipe or a minimum of one-third of the pipe diameter for large culverts.

Tips for opening blocked culvert

Motor graders are not only used to grade a culvert but they can be even used for reopening a blocked culvert. Typically, motor graders with crab steer attachment can be used for this purpose.

Below is the step by step process for doing so…

1. The grader’s front wheel should be positioned in the ditch on the side of the blockage. Here, it should be noted that the bottom of the ditch should be solid for this.

2. Then the rear frame of the grader should be kept on the road surface.

3. As the next step, the leading edge of the moldboard square should be turned to the mainframe and it should be angled at approximately two-thirds of the maximum forward tip.

4. The moldboard should be shifted to the side and the blade’s cutting edge should be extended into the ditch. Care should be taken for not damaging the culvert. After this, the angle of the blade should be set according to the culvert’s shoulder slope.

5. After following the above mentioned steps, you need to gradually move forward to remove the blockages. Later on the blade should be rotated to pull the material up onto the side of the road. In order to reach the bottom surface of the culvert, you may have to make multiple passes.

Overall, if you follow the tips stated above, then you can easily grade a culvert or open a blocked one through efficient motor graders manufactured by Mahindra Construction Equipment.

Filling the Gap: Operator Training for Todays Sophisticated Heavy Machines

activity is expected to push the sales of mining machinery too. Add to that the various flagship projects like the smart cities, the expansion of the national highways, construction of transport corridor connecting all the 4 metropolitan cities in the country, development of new airports and harbour ports and you will get a good idea about sharp hike in the demand for heavy machinery and its operators.

Now that we have established that heavy machinery operators are high in demand, we need to address the fact that there arent enough heavy machinery operators in the market to meet the increasing demand. Additionally, the number of adequately skilled and certified operators is even lower. For most part, the heavy machinery operators are novices trained by people in their network without much formal training. For most part, the sector involving heavy machinery operators is unorganised adding to the demand supply gap for good talent.

When it comes to India, the technology of the heavy machinery is developing at a rate like never before. The machinery is becoming increasingly sophisticated with the integration of software technology in most functions of the machines. The importance of machine to machine communication is gaining prominence with every passing day. It is no longer sufficient to understand only the mechanics of the heavy machines any more, one has to understand the latest tech integrated in the machines to make the most of it.

The ground reality however is quite a different picture. While the buyers are becoming educated and demanding, the operators are yet to catch up with the technology of these machines. Despite having technology to make their work easy at their finger tips, they still do things the old way simply because there aren’t familiar with the new technology.

Heavy Machinery operators usually require training before they can apply for their license. The training schools, especially government backed ones have outdated syllabus as is the case with their machines. The skills and training that the students gather from such exposure is inadequate to meet standards of work and efficiency that the industry demands. Over time, the big shots in the construction equipment industry have realised this widening gap and have taken it up on themselves to bridge this gap by coming up with their own training centres.

The OEM’s have come up with various training and certification courses that are held in various parts of the country to train and develop skilled operators. The graduates from these institutes are better equipped to make the most of the sophisticated technology that the OEM’s are coming up with. These graduates are better equipped to understand the fact that technology of the machines will keep getting upgraded and that they will also have to keep updating their skills if they want to remain relevant in the industry.

The lack of a nationally standardised syllabus and certification system has added to already wide gap between the demand and supply. Keeping the sorry state of these training institutes in mind, the private players like Mahindra & Mahindra in addition to a few others have come up with their own training institutes to increase the standard of skilled labour in this department. The curriculum is usually updated on a regular basis to stay relevant and practical training is usually intensive and on the OEM’s machines. Intensive hands on experience is a stringent requisite in the industry and the various private OEM operated institutes cater to this particular requirement. Mahindra for one has 5 such training institutes coming up in various parts of the country.

If we are to attempt at bridging this massive gap between the demand and supply of heavy machinery operators skilled at using the continuously evolving technology, a massive scale joint effort by the government and private players is required. A joint venture will combine the expertise of the private players and the reach of the government bodies to create a new evolved class of highly skilled heavy machinery operators to meet the demands of the industry. Today is the time to start these efforts, waiting any further will ensure a larger gap that will become even more difficult to fill.

Grading Systems Give Excavator Operators A Helping Hand

Over the years technology has been developed in both 2D and 3D options to help the operators take up seemingly difficult excavation jobs with tricky slopes and execute them with a grade that’s almost perfect. Lets take a look into how the new technology is changing how excavation jobs are executed and the improved end results that are made possible.

Various companies across the globe have been popping up in the last few years and have changed the way how hardware and software in a hydraulic machine interacts. Various companies have come up with 2D and 3D operation system that can help the operator get a better visual of the placement of the bucket, the required excavation grade and an overall better picture of the way things are happening on the ground with every move of the bucket. Sensors are placed to give the operator a virtual picture of the job at hand and its progress.

The new softwares come with both assisting and controlling options. When switched to an indicate mode of functioning the software gives only an indication of the relative positions of the variables in question and the details of the relative progress of the job at hand. The automatic control option on the other hand transfers all the control of the machine to the software and makes the whole process automated. Studies show that automated machines provide upto 25% more efficiency and time saving which can prove to be very beneficial to the company. Operators however are still reluctant to completely let go of control to a programmed software.

One rather unnoticed benefit of control systems is that it puts the operator in a position of complete control with regards to the quality and progress of the job instead of depending on the person on ground. Additionally having people on the ground while the machines are being operated at the site is unsafe. Corollary being that control systems make the job site much safer and more efficient as compared to those run exclusively by human operators without any software interference or control. While companies are favouring automated systems, operators are still skeptical of completely automated systems.

Internationally companies have tied up with the software manufacturers to install such control systems at delivery. Buyers that are two minds about opting for 2D or 3D control systems are given options of going with 2D systems and then upgrading it to the 3D ones if they feel the need for it. Additionally being given options of having indicator and compete control systems is supporting the cause of having operators putting in more faith in the systems. Additionally while the control systems require a delicate calibration they are robust and fortified to meed the harsh ground conditions.

Grading systems are yet to make their large scale debut in India and how the industry takes to these marvels is yet to be seen amongst other things.

Qualifications for a BHL Operator

Since they are highly technical, it is obvious that they would need trained operators who have expertise in safely handling the equipment to drive them as it goes without saying that any wrong move can cause heavy damage to the operator, equipment and even the people on the jobsite. Hence, it is always advised to have a qualified BHL operator.

The main task of a BHL operator includes driving and controlling the backhoe operations safely and as per schedule. He also need to operate various attachments as applicable and should know their respective functions. A BHL operator is also held responsible for the maintenance of the equipment. Apart from this, BHL operators should also be able to identify defects and malfunctioning of the equipment and in such a case, they are re required to take immediate action in terms of lodging complaints and getting the defects fixed.

In order to carry out all these tasks effectively and become a successful BHL operator, candidates need to possess certifications on earthmoving equipment operator/BHL from reputed institute or have proven work experience along license to drive heavy commercial vehicles like trucks etc.

Qualification, certification, and skills required by a BHL operator

Here are some general compulsory qualifications and personal attributes required to be a good BHL operator…

The general compulsory qualifications and attributes should include:

1. One of the most basic things that the BHL operator should have is the ability to independently operate the backhoe safely and responsibly.

2. Further, since, the operators are required to move the equipment from one site to another site on a commercial trailer or hauler, they must have a valid Heavy Commercial Vehicle Driving License (HCV).

3. Operators should also have experience of working in industrial environment involving moving earth or mining.

4. Operators should have on-the -job training or apprenticeship in backhoe operations with the construction company.

5. Operators should also know about carrying out pre-checks for various backhoe operations.

6. It is also required of the operators to have knowledge of various functions and use of the equipment and its various attachments like grappler fork, buckets, side shift forks, sweepers, crane hooks etc.

7. Not only knowing how to operate the BHL is important for the BHL operators but they should also know about how to maintain, troubleshoot, and store the equipment.

8. It is equally important for the BHL operators to know about the workplace safety requirements and procedures.

The personal attributes should include:

1. Operators need to have good communication skills so that they can clearly communicate and direct the co-workers to perform the relevant tasks.

2. Operating Backhoe Loaders can be physically strenuous and demanding, hence, physical strength and stamina is also very important for the operators so as to enable them to skilfully handle the equipment for long hours. They should be able to work in all weathers and must be prepared for both extreme heat and cold.

3. Operators should need to be polite and courteous and be able to respond to complaints.

4. Operators also need to have good hand eye coordination so as to comply with industry regulations.

5. Willingness to work and strong work ethics are equally desirable.

6. Last but not the least, operators should also have good eye sight and not suffer from colour-blindness.

Above mentioned general as well as personal skillset is extremely important for the BHL operators. Most of the operators acquire these skills during their training periods. Overall, given the technicalities involved in the BHL, it is always advisable to choose an operator who is qualified professionally or has proven experience in handling backhoe operations.

How to Make a Construction Site Safe

However here are some basic measures that companies can take to ensure a safe site free of any accidents

Basics first: Read up the basic safety precautions and requirements for the type of job site in question. Every one working and present on the job site should be well aware of the necessary precautions and safety rules on the construction sites. It is advisable for companies to have site safety sessions for its employees in addition to having compensation options and or insurance in place for its employees to support them in case of an accident. Employees should be well aware of the safety precautions to be observed on various parts of the job site.

Gear up: People on job sites should be properly geared with neon safety jackets, hard hats, proper gloves, shoes, ear and eye protection to start with. In case workers are required to work at heights, proper good quality harness should be used to ensure safety of the workers. The neon vests are mostly to ensure that people working on the site are easy to notice in both cases to prevent accidents and to find the employees in case of an accident. Good quality safety gear should be made mandatory on job sites.

Danger Zone: Depending on the top type of construction site in question, the area should have the required cones and partitions to mark the site and the caution zones. Buildings usually have a grill type fence to prevent people from falling while road and bridge sites have huge partitions to keep all non essential personnel away from the job site and its various extra caution zones. Additional safety in form of scaffolding help stop keep the debris falling on workers on the site and injuring them.

Heat and electricity safety: All wires, live and otherwise should be handled with utmost care. Safety gear used on the site should not conduct heat and or electricity to ensure safety of the workers. No wires or water lines should never be left unattended since it may cause serious injury.

Untrained/ unqualified workers: Most workers and operators on the job site are uneducated people with little or no formal training of working on one. Many operators learn how to operate the machinery form people they know and miss out on crucial information that can possibly lead to accidents on the job site. With limited scope for formal education in the field, the safety on a job site is compromised at the very basics.

Simple measures and combined efforts are required to ensure job site safety failing which accidents on the site can cost the company heavily in terms of both time and money.

Safety Tips for Operators of Heavy Earth Moving Equipment

The last thing you would want on a job site is non-working equipment due to improper maintenance, frequent breakdowns, thereby slowing down your operations. Here are some safety tips for operators of heavy earth moving equipment to keep the machine up and running all the time…

1. Safety tips for driving and operating heavy equipment

  • Operators must check the heavy machinery thoroughly before driving and operating for anything amiss.
  • Before starting the equipment, ensure that the equipment has been serviced according to the schedule.
  • Many attachments are used with the heavy earth moving equipment including backhoe loaders and the like. Hence, see to it that as a responsible operator, you lower all the attachments and set the brakes.
  • Operators should also ensure that the work area is absolutely clear before moving or backing up the equipment.
  • Make sure that you don’t leave the machine on a slope with the engine running as this may put the machine into motion.
  • Take extra care while working near the edges of cuts or fills.

2. Safety tips for maintenance and repair of heavy equipment

  • Operators should ensure that the engines are completely shut off and keys are removed before carrying out any repair or maintenance activity.
  • Lubricate all the moving parts of the machine well as they will fail if they aren’t lubricated properly. Too little as well as too much lubrication can be harmful for the machine. So, you need to lubricate the machine wisely.
  • Keep the engine completely shut off while refuelling the equipment.
  • Another great tip for properly maintaining the equipment is to make sure it stays as clean as possible and dirt and debris are removed regularly.
  • Earth moving machinery parts are fitted with special seals and filters designed to keep dirt and grime out of sensitive areas. Hence, broken seals must be repaired immediately, breathers must be kept clean and all filters should be inspected regularly and changed when they become dirty or clogged.
  • If possible, keep the equipment housed in a building.
  • Create and follow a maintenance schedule. Include notations on how often each part of the machinery should be inspected for problems, repairs and general maintenance.
  • Pay close attention to wear and tear signs as they may signal problems that can cause machinery to malfunction more often or result in costly repairs or component replacements before your regular inspection. Some common signs of wear and tear are vibration, heat and belt shape.

3. Safety tips for parking and security of heavy equipment

  • Make sure that as operators of the heavy equipment, you lower the attachments and set the parking brake and put the lever in the neutral position before dismounting the equipment after the day’s work.
  • Park the equipment in such a way that it does not obstruct the traffic.

Thus, as responsible operators of heavy earth moving equipment, you need to follow these tips to operate the equipment safely, increase its lifespan and prevent dangerous injuries. These small but important tips can help you to increase productivity as well as efficiency of the machine.

Backhoe Loader Safety Guidelines

Backhoe loader operators need to be adequately trained and companies need to have stricter policies about safety compliance to reduce the number of accidents and mishaps. Given below are some basic backhoe loader safety guidelines that need to be followed when handling a backhoe loader.

Know your machine well: Make it a point that the operator is well versed with the manual of the machine being operator. Not backhoes in general but the exact machine to be operated since over confident operators cause more accidents than the newbies. Additionally the operator should be familiar with the controls of the machine in question.

Survey the site: Ensure that there are no utility lines at the dig site that can possibly be damaged. Similarly keep an eye for power cables above when lifting things. Damage to utility lines like electricity lines can not only cause heavy damage to both the operator and the machine.

Bucket down: Always ensure that the bucket stays lowered and near the machine as much as possible for stability. The bucked should be raised only when dumping needs to be done. Its also helps ensure that the whole dig site is visible and that no unrequited personnel are around.

Stabilisers down: Always check the placement of the stabilisers and that the ground underneath is stable enough. Soft soil under the stabiliser legs can lead to cave ins and cause damage to the machine, its operator and the people around.

Gear check: The backhoe should not be in gear when starting it. As a rule of thumb always check before the engine is started. By passing this safety measure can have hazardous repercussions.

Load up: When lifting heavy weights with the front loader, ensure that adequate counter weight is used at the back to prevent the machine from tipping.

Clean up: Always ensure that the steps and platforms are kept clean of any kind of debris, tools or parts.

Shut down: The machine should be shut down before the operator enter the cabin and only once it is shut down again after use should the operator dismount from the machine. One should never mount or dismount a backhoe when it is being operated.

By stander free: The vicinity where a backhoe is being operated should be clear of any bystanders. Rear view mirrors should be kept clean to keep an eye out for people at the back of the machine. Additionally, back up alarms should be used when the machine is being operated in reverse gear.

Hydraulic check: Manually and visually check for any hydraulic leaks and malfunctions after maintenance and before the machine is set to be operated. Malfunctioning hydraulics can be disastrous.

Simple safety checks and compliance with the guidelines can help prevent many a mishaps and loss of man and money.

Important Safety Measures When Using a Backhoe

Here are some basic safety measures to keep in mind when operating one of these machines.

  • Hard hat it: Using a bright colored hard hat is a must for all working on a site where the backhoe is being operated and the operator too. Any site where ECE are being used, by default become hard hat regions making use of a hard hat mandatory. The bright color of the hard hat is to make sure that it draws enough attention towards people wearing it. It helps prevent accidents by warning the backhoe operator of people within the working radius of the machine. Additionally, hard hats protect the wearer from head injury and consequently brain damage in case of an accident.
  • Bright colored vest: The vest again is mostly for catching attention with its bright neon colors. While the vests do not do much to protect the body from injury in case of an accident, they do reduce the chances of people being injured around a working machine.
  • Safety belt is safety first: The safety belt while small is one of the most important measures that need to be in place for safety of the operator. It is this seemingly simple looking but sturdy belt that helps keep the operator safe when inside the cabin. A safety belt should always be used no matter how experienced or confident the operator is. It is the safety belt alone that will keep the operator safe in case the loader tumbles for any reason.
  • Construction cones to the rescue: Highway cones, safety cones, construction cones all refer to the same brightly colored cone shaped plastic markers that we often see on roads and construction sites. These cones should be used to outline the job site where the backhoe is being used. It warns people of construction working going on in the area and that stepping in the area can be fatal.
  • Drive slow: backhoes are capable of being driven at speeds as high at 25 kmpl and above. While capable of speed, backhoes should always be driven at slow speeds to prevent accidents of both the machine and of the people working on the site. Machines are likely to topple over if driven to fast when the weight is not centered.
  • Say no to the joy rides: As Indians we usually find it difficult to say no to people asking for a short ride across the job site. However, the backhoe is strictly a single person machine. No matter who and why, no other person other than the operator should be riding the backhoe at any given point of time. It shifts the center of gravity away from the center of the machine and increases the possibility of the machine loosing balance and toppling over.

Oldest or latest machinery for construction doesn’t matter unless the safety measures are in place and followed, especially in a county like India where safety of workers is barely given any regard.

How to Operate a Backhoe Loader

While the number of machines being used are increasing the number of skilled operators are yet to keep pace with the new machines that rely more on technology these days. While there aren’t many training schools or certified courses available in India at the moment, the PM Modi’s skill India campaign and efforts by the private players are all set to change that and create new and well-paying job opportunities.

Here is our small 101 on how to operate a backhoe loader to give you a brief idea as to how simple if not easy operating a backhoe can really be.

  • Read up to familiarize: Read the literature provided by the manufacturer of the machine to get a good idea of the capacity and controls of the machine. One you have read the brochure, get in the cab and do a practical examination to get familiar with the controls and how they are placed and function. While operating the backhoe requires a lot of hand to eye co-ordination, the trick lies in getting a feel for the hydraulics and how they work.
  • Get down to it: First off the safety precautions need to be ticked off the checklist and then begins the fun. Get the stabilizers down for stability and then release the boom from its lock. Depending on your backhoe’s controls, extend the stick and open the bucket.
  • Put the boom to work: Once you have opened the bucket, lower the bucket to put it to use. Keep in mind that the backhoe is a rather huge machine and so should be used with care so as not to damage things and or people on and around the dig site.
  • Let the digging begin: Using the appropriate controls, curl the bucket inward and lower it at an angle to scoop up the soil.
  • Lift it up: Once the soil has been scooped, use the controls smoothly in union to retract and raise the boom while keeping the bucket curled. Make it a point that the bucket is not filled beyond capacity. Usually most backhoes provide a 14 feet reach while an extend a hoe provides another 4 feet.
  • Dump it: Once filled, use the controls to open the bucket, pull the stick in closer and dump the scooped soil. Make sure it is not done too fast as it can cause the backhoe to tip.

These are just a few basic steps on how to operate a backhoe’s basic function of digging and dumping the scooped up soil. While operating one of these machines is no rocket science, it isn’t a piece of cake either. It requires a lot of practice and persistence to become a skilled operator and utilize these amazing machines to their full potential.

Tips to Help You Operate a Mini Excavator

Apart from digging, mini excavators can do grading, lifting heavy items and compacting a subgrade. Based on the digging depth of the boom and bucket, mini excavators come in various sizes.

While you can have a dedicated person to operate the mini excavator, you can even operate it on your own to save time and money. Well, you may be wondering as to how to operate a mini excavator without prior experience. Fret not! We share some tips to help you operate a mini excavator on your own.

Tips on How to operate a mini excavator better

  • The first step is to read the operators’ manual to get familiar with the controls’ location and description. You also need to read the warning labels and stickers as well as maintenance information, specification charts and other important information posted around the machine.
  • Now, get ready for the action and enter the mini excavator form the side by stepping on the track and then entering the roll cage.
  • Sit firm in the operator’s seat. Study and get familiar with the controls.
  • Fasten the seat belt in order to ensure your safety as mini excavation might tip over.
  • Hold the joysticks and move them around to know how they work. This is important because they control the bucket/boom assembly and the swivel. While the right side joystick controls the front boom and bucket curl, the left joystick controls the back knuckle and machine swivel. By default, these joysticks return to the neutral position when they are released. Learn to operate these joysticks.
  • Look down between your legs to locate two long steel rods with handles attached on the top. These are the drive/steer controls, which control the rotation of the track on the side it is located.
  • You will also find two hand controls located directly in the front of the roll cage. The left control is used to run the left track and the right control to run the right track. The mini excavator can be moved forward and backwards by using these hand controls together.
  • On the right side, in front of the instrument cluster, there will be two more levers. The first lever is the throttle which is used to adjust the engine speed and the second is used for controlling the front blade movement i.e., up and down.
  • After learning and understanding the controls, locate the ignition key on the back right and turn it on to start the machine.
  • Now start manoeuvring the machine. However, always make sure that both the hoe boom and front blade are raised.
  • Move the machine, turn it and take it back to get used to the handling mechanism and speed. In order to try out the various functions of the machine like digging etc., find a suitable place.

To sum up

Keep on practicing with all the controls till you feel confident as all said and done, mastering the art of operating the mini excavator will take some time. So, get going!